Elastic headwear

ABSTRACT

Elastic headwear has a head covering portion being stretchable in at least a circumferential direction thereof, and a sun shield connected to the head covering portion. The sun shield is stretchable in at least the circumferential direction of the head covering portion. The elastic headwear is capable of stretching throughout its whole portion since the sun shield as well as the head covering portion can stretch in the circumferential direction.

BACKGROUND OF THE INVENTION

-   -   (a) Field of the Invention

The present invention relates to elastic headwear, and more particularly, to elastic headwear that can accommodate a wider range of head sizes.

(b) Description of the Related Art

Conventional elastic headwear, such as a cap and a hat, includes an elastic crown portion and a stiffened sun shield that is coupled to the elastic crown portion. The elastic crown portion of the headwear is composed of a plurality of pieces that can stretch in a circumferential direction to accommodate a variety of head sizes. However, because the stiffened sun shield is not stretchable, the amount that the elastic crown portion can stretch is limited. That is, since the stiffened sun shield encompasses a part of the circumference of the crown portion of a hat, the crown portion cannot be freely stretched. In a baseball cap, front pieces of the crown portion, to which the stiffened sun shield is coupled, are stiffened in order to retain the shape of the headwear, and therefore only the remaining pieces of the crown portion can stretch according to the head size.

Therefore, the conventional elastic headwear fits a somewhat limited range of sizes due to the sun shield, so it cannot cover head sizes from children to adults.

Further, the stiffened sun shield may reduce the wear comfort because its edge is likely to press against the head of a wearer.

SUMMARY OF THE INVENTION

In view of the prior art described above, it is an object of the present invention to provide elastic headwear having an elastic head covering portion being capable of stretching throughout its whole portion to accommodate a wider range of sizes.

It is another object of the present invention to provide elastic headwear having a comfortable fit regardless of head size.

To achieve these and other objects, as embodied and broadly described herein, elastic headwear includes: a head covering portion being stretchable in at least a circumferential direction thereof; and a sun shield connected to the head covering portion. The sun shield is stretchable in at least the circumferential direction of the head covering portion.

The sun shield preferably has an elastic cover and at least one stretchable interlining having a shape retaining property. The interlining preferably has at least one non-woven fabric layer of polyester and at least one polyurethane layer.

The elastic headwear preferably has a stretchable back lining, stitched or adhered to an inside of the head covering portion, for retaining a shape of the head covering portion.

The elastic headwear preferably has a stretchable sweatband connected to an interior circumference of the head covering portion. The stretchable sweatband comprises a plurality of line cutting sections. Each line cutting section is formed perpendicular to the circumferential direction.

According to another aspect of the present invention, a method of forming elastic headwear includes:

-   -   forming a head covering portion to be worn on a head of a         wearer, the head covering portion being stretchable in at least         a circumferential direction thereof; and     -   forming a sun shield connected to the head covering portion,         being stretchable in at least the circumferential direction of         the head covering portion.

Both the foregoing general description and the following Detailed Description are exemplary and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and, together with the description, serve to explain the principles of the invention:

FIG. 1 illustrates a perspective view of elastic headwear according to a first embodiment of the present invention;

FIG. 2 illustrates a bottom view of the elastic headwear of FIG. 1;

FIG. 3 shows a sectional view along A-A line of FIG. 1;

FIG. 4 illustrates an interlining which is applicable to the headwear of FIG. 1;

FIG. 5 illustrates a perspective view of elastic headwear according to a second embodiment of the present invention;

FIG. 6 illustrates a bottom view of the elastic headwear of FIG. 5;

FIG. 7 illustrates a stretchable sweatband which is applicable to the headwear of FIG. 5; and

FIG. 8 illustrates a perspective view of elastic headwear according to a third embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the present invention will hereinafter be described in detail with reference to the accompanying drawings, where like numerals of reference designate like elements throughout.

Referring first to FIGS. 1-2, a hat according to a first embodiment of the present invention will be described. The hat has a crown portion 10 and a sun shield 30. The crown portion 10 serves to cover the wearer's head, and the sun shield 30 is coupled to the crown portion 10 around its entire lower hem. The hat preferably has a stretchable sweatband 60 connected to an interior circumference of the crown portion, as shown in FIG. 2.

The crown portion 10 has stretchability in at least a circumferential direction thereof, and can be made of elastic fabric or any kind of elastic material.

The sun shield 30 is also stretchable in at least the circumferential direction of the crown portion, which is an arrow direction of FIG. 1. As shown in FIG. 3, the sun shield 30 has a cover 40 formed of stretch fabric or stretch synthetic resin and one or more interlinings 80 therein. Although two interlinings 80 are shown in FIG. 3, the number of interlinings is variable from one or more according to a specific design.

The material of the interlining 80 is elastic fabric or any kind of elastic material which can retain the shape of the sun shield 30. As shown in FIG. 4, the interlining 80 has a non-woven fabric layer 80 a of polyester, a polyurethane layer 80 b formed on the layer 80 a, and another non-woven fabric layer 80 c of polyester formed on the layer 80 b. Each of the non-woven fabric layers 80 a, 80 c have a predetermined thickness and stretch to some extent due to the fabric characteristics. The non-woven fabric layers 80 a and 80 c may retain the shape of the sun shield 30.

The polyurethane layer 80 b has high elasticity to give the stretchability to the sun shield 30.

Therefore, the sun shield has an interlining 80 to retain the shape thereof as well as to be stretchable.

Although the interlining 80 as shown in FIG. 4 has three layers, the interlining according to the present invention is not limited to this construction, but can be made of any kind of elastic material which has a shape-retaining property.

FIG. 3 shows that sewing threads 50 are stitched to connect the crown portion 10 with the sun shield 30, sewing threads 70 are stitched to connect the crown portion 10 and the sun shield 30 with the sweatband 60, and sewing threads 90 are stitched to connect the cover 40 with the interlining 80.

The sewing threads 50, 70, and 90 are preferably selected from elastic yarns such as polyurethane covered yarns, polyurethane yarns, textured yarns, and high-twist yarns.

The sewing threads 50 have an upper thread 50 a having a relatively high stretchablility and a bobbin thread 50 b having a high stretchability. The upper thread 50 a is preferably made of nylon series yarns, such as nylon 210D. The bobbin thread 50 b is preferably made of polyurethane yarns.

The sewing threads 90 have an upper thread 90 a having a high stretchablility and a bobbin thread 90 b having a high stretchability. The upper thread 90 a is preferably made of polyester 50's/3 yarns, and the bobbin thread 90 b is preferably made of polyurethane covered yarns with a high stretchability.

When a wearer wears the hat as shown in FIGS. 1-2, the cap stretches in the circumferential direction. Specifically, the crown portion 10 stretches in the circumferential direction, so the sun shield 30 also stretches in the circumferential direction. Further, the sewing threads 50, 70 and 90 are stretchable to enhance the stretchability of the hat. Since the crown portion 10 may stretch throughout its whole portion, resulting in a wider stretch range, it can accommodate a variety of head sizes from children to adults. Although the sun shield 30 is not formed of a stiffened material, it is capable of retaining its shape.

Referring to FIGS. 5-6, a cap according to a second embodiment of the present invention has a crown portion 1 and a sun shield 3. The crown portion 1 serves to cover the wearer's head, and the sun shield 3, which is coupled to a front part of the crown portion 1, serves to shade the wearer's face and eyes when the cap is worn. The crown portion 1 is composed of a plurality of elastic pieces 1 a-1 f which have stretchability in at least a circumferential direction of the crown portion 1. Each elastic piece is not limited to fabric, but can be made of any kind of elastic material.

Stretchable back linings 5 and 7 are stitched or adhered to the inside of the front pieces 1 a and 1 b of the crown portion 1 in order to retain the shape of the crown portion 1. The stretchable back linings 5 and 7 have stretchability in at least a circumferential direction of the crown portion 1. The material of the back linings 5 and 7 may be selected from stretch fabric or stretch synthetic resin.

The sun shield 3 is also stretchable in at least the circumferential direction of the crown portion, which is an arrow direction of FIG. 5. The material of the sun shield 3 may be selected from stretch fabric or stretch synthetic resin. The sun shield 3 preferably has a construction of FIG. 3 or FIG. 4. That is, the sun shield 3 has a cover formed of stretch fabric or stretch synthetic resin and one or more interlinings therein. The material of the interlining is elastic fabric or any kind of elastic material which can retain the shape of the sun shield. The interlining may have a non-woven fabric layer of polyester and a polyurethane layer.

The cap preferably has a stretchable sweatband 9 connected to an interior circumference of the crown portion, as shown in FIG. 6. As shown in FIG. 7, the sweatband 9 has a plurality of line cutting sections 9 a along the lengthwise direction in order to stretch in a wider range. Each line cutting section 9 a is preferably formed perpendicular to the lengthwise direction.

When a wearer wears the cap as shown in FIGS. 5-6, the cap stretches in the circumferential direction. Specifically, all pieces 1 a-1 f of the crown portion 1 stretch in the circumferential direction, so the sun shield 3 which is connected to the front pieces 1 a-1 b also stretches in the circumferential direction. The stretchable back lining 7 as well as the sweatband 9 of the crown portion 1 also stretch in the circumferential direction. Therefore, the crown portion 1 may stretch throughout its whole portion, resulting in a wider stretch range to accommodate a variety of head sizes from children to adults.

Referring now to FIG. 8, a visor cap according to a third embodiment of the present invention will be described. The visor cap has a rim portion 11 for encircling the head, and a sun shield 31 coupled with a front side of the rim portion 11.

The rim portion 11 can be provided as either a single piece or as several pieces, which are stretchable in at least the circumferential direction.

The sun shield 31 is also stretchable in at least the circumferential direction of the crown portion, which is an arrow direction of FIG. 8. The material of the sun shield 31 may have the construction of FIG. 3 or FIG. 4.

It is possible to apply a stretchable back lining that is stitched or adhered to the inside of the rim portion 11 in order to retain the shape of the rim portion 11. A stretchable sweatband is also applicable to the interior circumference of the rim portion 11, although is not shown in the drawing. It is possible to use the stretchable sweatband shown in FIG. 7.

Similar to the cap as shown in FIG. 5, the visor cap may stretch throughout its whole portion, resulting in a wider stretch range accommodating a variety of head sizes from children to adults, when a wearer uses it.

Although it is not shown in the drawings, it is possible to apply a stretchable back lining that is stitched or adhered to the inside of the crown portion of a hat in order to retain the shape of the crown portion 10. A stretchable sweatband of FIG. 7 is also applicable to the interior circumference of the crown portion of a hat.

The present invention is not limited to the caps and hat described above, which merely show examples of a kind of application, and it may be applied to various other kinds of headwear.

As described above, according to elastic headwear of a preferred embodiment of the present invention, elastic headwear is capable of stretching throughout its whole portion since the sun shield as well as the head covering portion can stretch in the circumferential direction. The headwear has a wider stretch range accommodating a variety of head sizes from children to adults.

While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. 

1. Elastic headwear comprising: a head covering portion being stretchable in at least a circumferential direction thereof; a sun shield connected to the head covering portion, being stretchable in at least the circumferential direction of the head covering portion.
 2. The elastic headwear as recited in claim 1, wherein the sun shield comprises: an elastic cover being stretchable in at least the circumferential direction of the head covering portion; and at least one interlining formed in the elastic cover, the interlining being stretchable in at least the circumferential direction of the head covering portion and having a shape retaining property.
 3. The elastic headwear as recited in claim 2, wherein the interlining comprises: at least one non-woven fabric layer of polyester; and at least one polyurethane layer.
 4. The elastic headwear as recited in claim 1, further comprising: stretchable sewing threads being stitched to connect the head covering portion with the sun shield.
 5. The elastic headwear as recited in claim 2, further comprising: stretchable sewing threads being stitched to connect the cover with the interlining.
 6. The elastic headwear as recited in claim 1, further comprising: a stretchable back lining being stitched or adhered to an inside of the head covering portion and retaining a shape of the head covering portion.
 7. The elastic headwear as recited in claim 1, further comprising: a stretchable sweatband connected to an interior circumference of the head covering portion.
 8. The elastic headwear as recited in claim 7, wherein the stretchable sweatband comprises a plurality of line cutting sections, each line cutting section being formed perpendicular to the circumferential direction.
 9. The elastic headwear as recited in claim 7, further comprising: stretchable sewing threads being stitched to connect the head covering portion and the sun shield with the sweatband.
 10. A method of forming elastic headwear, comprising: forming a head covering portion to be worn on a head of a wearer, the head covering portion being stretchable in at least a circumferential direction thereof; and forming a sun shield connected to the head covering portion, being stretchable in at least the circumferential direction of the head covering portion.
 11. The method as recited in claim 10, further comprising: forming a stretchable back lining, which is stitched or adhered to an inside of the head covering portion, for retaining a shape of the head covering portion.
 12. The method as recited in claim 10, further comprising: forming a stretchable sweatband connected to an interior circumference of the head covering portion. 